Corrugating Roll Unit Conveyance Apparatus for Efficient Replacement
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Solution Overview
Problem
Existing corrugating roll unit replacement processes are inefficient, requiring frequent manual movement of carriages and often interfering with worker operations due to permanently installed guide rails, which also limit space for installation on the driving side of corrugating machines.
Innovation Solution
A corrugating roll unit conveyance apparatus with a mounting base and movement device that allows for the corrugating roll unit to be replaced with the movement of one carriage, using a combination of horizontal and vertical travel mechanisms and a switching device to navigate around obstacles, and a belt support mechanism to prevent damage to the pressurizing belt during replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If permanently installed guide rails are used for carriage movement, then the carriage can be reliably positioned for roll unit replacement, but the guide rails interfere with worker movements and various operations
Solution Approach 1:
The patent removes the permanently installed guide rails from the system and replaces them with a portable carriage that has its own movement mechanism. This extraction eliminates the interference with worker movements while maintaining the carriage's ability to be reliably positioned through its self-contained drive system and positioning mechanisms.
Solution Approach 2:
The patent transitions from a static, permanently installed guide rail system to a dynamic, mobile carriage system. The carriage can move autonomously to positioning locations and can be repositioned as needed, providing both reliability through controlled positioning and flexibility for worker operations.
2Ease of operation
If guide rails are installed on the operation side of the corrugating machine, then the carriage can access the single facer for replacement work, but the guide rails interfere with the work line and various quick work operations
Solution Approach 1:
The patent extracts the carriage from the permanently installed guide rail system and makes it self-contained with its own movement capabilities. This allows the carriage to access the single facer without requiring permanently installed guide rails that would interfere with work operations.
Solution Approach 2:
The portable carriage acts as an intermediary between the worker and the single facer. It provides the necessary positioning and support functions without requiring permanent infrastructure that would obstruct work operations, thereby mediating between accessibility needs and operational freedom.
3Device complexity
If a single carriage is used for both removing and mounting corrugating roll units, then the replacement process is simplified, but the carriage must perform multiple functions requiring complex mechanisms
Solution Approach 1:
The patent designs the carriage with multi-functional capabilities to handle both the removal and mounting of corrugating roll units. The carriage is equipped with positioning mechanisms, support structures, and movement systems that enable it to perform multiple functions in the replacement process, thereby simplifying the overall procedure while maintaining adaptability.
Solution Approach 2:
The carriage employs dynamic positioning and adjustment mechanisms that allow it to adapt to different operational modes (removal and mounting). These mechanisms provide the necessary versatility without permanently fixing the carriage to a single function, enabling simplified yet flexible replacement operations.
4Productivity
If the carriage moves frequently to predetermined positions for manual replacement work, then the replacement can be performed, but the replacement work time becomes long and workability burden increases
Solution Approach 1:
The patent equips the carriage with self-contained movement and positioning capabilities, allowing it to autonomously navigate to predetermined positions without requiring frequent manual intervention. This self-service capability reduces the time and labor required for replacement operations while maintaining productivity.
Solution Approach 2:
The carriage is pre-positioned and prepared with necessary components before replacement operations begin. Its ability to autonomously move to predetermined positions and prepare for replacement work in advance reduces the overall time required for the replacement process while maintaining efficient productivity.
Data Source
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AI summary
A corrugating roll unit conveyance apparatus and an apparatus and a method for replacing a corrugating roll unit comprise: a mounting base (111) having a first accommodation part (N1) for accommodating a corrugating roll unit (40) to be removed and a second accommodation part (N2) for accommodating a corrugating roll unit (40) to be installed; and a movement device (112) for moving the mounting base (111) to a first replacement position at which the first accommodation part (N1) faces the existing corrugating roll unit (40), a second replacement position at which the second accommodation part (N2) faces a space (N3) from which the existing corrugating roll unit (40) has been removed, and a retracted position separated from the first replacement position and the second replacement position.